PLL tuned HF Tesla Coil for Plasma

Loudspeaker
1
Bill Slade
Ver. 1.2, March 5, 2007
1This work has not been peer reviewed, so any assertions made in this paper should be thoroughly
checked by the reader. Although the author has tried to avoid errors, they may exist. Readers are
encouraged to contact the author with possible errors, comment s and questions. The author
assumes no responsibility for the consequences readers may suffer attempti ng to construct this
device. In short, you build this device at your own risk! This paper is intended to fulfill no other
purpose than to be an educational exposition of an electrical engineering problem. This is a work in
progress. Last modified: 2007- 03- 05. This work is licensed under the Creative Commons
Attribution- Noncommercial - Share Alike 2.5 License. To view a copy of this license, visit
http: / / cr eativecommons. org/ licenses / by- nc- sa/ 2. 5/ or send a letter to Creative Commons, 543
Howard Street, 5th Floor, San Francisco, California, 94105, USA.
Class- E Tesla coil notes, Bill Slade 1
1. Project summary:
This project was undert aken with the goal of developing an efficient continuous
wave (CW) solid state Tesla coil operating above 3MHz. The attempt to construct
this device was inspired by the work of Dan McCauley at EasternVoltResearch [1]
and experiment s carried out by the keen experimenters at 4hv.org. In conjunction
with this, it was also desired to design and const ruct a suitable modulator for
producing high quality sound from the plasma discharge. Some preliminary
specifications for the Tesla coil and RF stages are:
1. Power amplifier (PA) output (typ): 200- 250 Watt
2. PA supply: 100- 120VDC
3. PA efficiency: > 90%
4. Operating frequency: 4.5 MHz
5. PA input signal level: 5V (TTL- level)
6. VCO freq range: 4.0- 5.0MHz
7. PLL loop bandwidt h: >50kHz
8. BW of drain low- pass network: >15kHz
9. Drain LP network attenuation at 4.5MHz: > 100dB (conducted limits should
be below 56dBuV)
10. Measured RF electric field at 300m: < 15uV/ m (based on FCC part 18 for ISM
devices on non- ISM bands).
Preliminary specifications for the modulator are:
1. Drain supply voltage: 100- 120V
2. Output PWM duty cycle: 0 < d < 90%
3. Clock frequency: 200kHz
4. Output voltage: 100V
5. Clock ripple on power supply: < 0.5V
6. Effective audio band: 20Hz 15kHz
The overall system outline should enhance flexibility, so that various experiment s
can be tried in the interest of studying the Tesla coil behaviour and optimising
output. Figure 1 shows the proposed self tuning Tesla coil system.
This project progressed in three stages. The first was to develop a suitable class- E
(or similar) power amplifier and matching scheme to the Tesla coil resonat or. As
will be seen later, it is a challenge to maintain the efficient class- E like amplifier
behaviour over different levels of plasma power in the Tesla coil as a result in
shifts in capacitive and resistive loading caused by variations in discharge size.
Certain precautions need to be observed to reduce undesired (and illegal)
interference and to enhance safety.
The second task was to develop a special phase- locked- loop (PLL) that was capable
of generating quadrat ure (at 0 and 90 degrees) VCO output signals. The PLL uses a
pickup antenna near the Tesla coil resonat or to sample the phase of the electric
field near the top of the coil for the self tuning mechanism to work properly.
Developing a stable PLL loop requires a bit of though and care to detail. Some
aspects of PLL design will be discussed as well as precautions that need to be taken
to prevent interference from the PA stages.
Class- E Tesla coil notes, Bill Slade 2
The modulator is based on the ubiquitous TL494 switch mode power supply chip
operating as a pulse- width modulator. It operates at high speed (important to get
high audio quality and to reduce the size of transfor mer). Details on important
design considerations are given to assist experiment ers. As with the Tesla coil,
some care needs to be taken to reduce electromagnetic interference, given the high
clock speeds and sharp switching transitions encount ered in this subsystem.
Now the disclaimer. I do not want to see any news report s about someone killing or
injuring him/ her self building musical Tesla coils in the backyard shed! As always,
anyone who experiment s with these types of circuits does so at his or her own
risk. There are high voltages invol ved as well as dangerous levels of
continuous wave RF power which can cause intensel y painful and possibl y
life- threatening burns. Be sure that you know what you are doing. The
author attempts to point out possibl e safety hazards in the course of this
document, but there is no guarantee that these warnings are definitive. It is up
to you to use common sense. If you are not sure about a safety issue, ask
someone who knows. Do not attempt somethi ng if you are unsure. Always be
aware that the death of yourself and/ or someone else is a likely penalty for
your mistakes! Know the risks!
Be aware that you are also responsibl e for keeping any electromagnetic
interference within legal limits. This document describes the construction of
high power RF circuits capable of causing harmful unintentional interference
by RF coupling into power supplies, nearby cables and metal objects. Be sure
to use adequate decoupling in circuits and use RF tight enclosures for system
component s.
Finally, use appropriately rated fuses and/ or circuit breakers in your power
supplies. Short circuits will result in fire and possibl e burns to yourself or
others as well as possible destruction of valuable property. When you use an
oscilloscope, voltmeter, ammeter or any other test instrument, make
absolutel y sure you know what you are doing!
2. Plasma Generation/ CW Tesla Coil
The initial step is to develop a plasma source. For this, we rely on a modern
variation on a very old technology: the Tesla Coil.
2.1 The resonator
The resonat or consists of about 25 m of PVC insulated 1.5mm
2
copper wire close
wound on a 90mm diameter PVC coil form (a 35cm long piece of PVC drain pipe). It
is important that the form material have low loss at the operating frequency
(approximately 4.5 MHz). PVC pipe is a good perfor mer in this service as long as
the coil windings do not get too hot (lower than 50 or 60 C). I ended up with
about 85 turns on the form, forming a solenoidal secondary length of about 25 cm.
(This will depend on the thickness of the insulation on the winding wire.)
At the bottom of the secondary winding, 10 turns of 1.5mm diameter enameled
copper wire were close wound on top of the secondary winding. Th ends can be
Class- E Tesla coil notes, Bill Slade 3
held in place by feeding the wire ends through holes in the bottom of the form or
held in place with electrical tape. Figure 2 shows a photo of the completed coil
resonat or.
It is worth mentioning that there is nothing special about the resonant frequency of
the resonat or. The original a priori design criterion for the resonant frequency was
that it be around 3- 5 MHz. It turned out that a standar d package of 25m of wire
wound on the 90mm pipe should give a frequency in that range.
2.1.1 Modeling the resonator with NEC
Further study of the open resonat or were carried out using the NEC solver [2]. This
software is usually used for solving antenna problems, but any open struct ure is
Class- E Tesla coil notes, Bill Slade 4
Figure 2: Picture of energised
Tesla coil resonator in its "cage"
with two standard fluorescent
tubes.
Figure 1: Proposed PLL based self - tuning Tesla coil for operation between 4 and 5
MHz.
conveniently solved. Even resonator loaded and unloaded Q factors can be
comput ed as well as resonant frequencies. See Appendix A for some background
theory on the NEC package as well as where to find the software and its user
manuals. In the meanti me, let us present some results which help us gauge the
feedpoint impedance of the primary fed resonat or under various conditions of
loading. This will also help us to estimate the coupling between the primary and
the secondary windings.
Using the NEC package means assembling a geomet ric model of our coil. We
neglect the plastic of the coil form and the wire insulation and assume all air
dielectric. The winding diameter and pitch can be chosen and we get somet hing
that looks like the cross- section picture in Figure 3.
The input file to NEC is given by:
CM *******************************************************
CM ** Model of a coupled HF Tesla coil resonat or **
CM ** Comput e S11 **
CM ** primary excited w/1. 0. **
CM ** Dimensions are: **
CM ** **
CM ** Bill Slade **
CM ** 17- 3- 2006 **
CM *******************************************************
CE
GH 1 2000 0.00258 0.232 0.045 0.045 0.045 0.045 0.0001
GM 0 0 0. 0. 0. 0. 0. 0.01 1.0
GH 3 200 0.00258 0.01295 0.048 0.048 0.048 0.048 0.0001
Class- E Tesla coil notes, Bill Slade 5
Figure 3: Schematic of resonator geometry. Note that
drawing is not to scale.
GM 0 0 0. 0. 0. 0. 0. 0.01 3.0
GA 4 10 0.01 0. 90. 0.0001
GM 0 0 0. 0. - 90. 0.045 0. 0. 4.0
GW 5 15 0.048 0. 0.01 0.068 0. 0.01 0.0001
GW 5 15 0.068 0. 0.01 0.068 0. 0. 0.0001
GW 7 15 0.0476445857 0.00583039067 0.02295 0.068 0.0023370052 0.01518
0.0001
GW 7 15 0.068 0.0023370052 0.01518 0.068 0.0023370052 0.0 0.0001
GE 1
GN 1 0 0 0 0. 0. 0. 0. 0.
FR 0 30 0 0 4.70 0.005
EX 0 0 2269 1 1.0 0.
LD 0 0 2268 2268 50. 0. 0.
XQ 0
PT - 2
EN
The frequencies of the fundament al modes of the inductively coupled Tesla coil
resonat or are found where the imaginary part of the admittance (the blue curve)
experiences a zero crossing in Figure 4. This happens first around 4.71MHz and
corresponds to a parallel resonance. That is, the point where the feedpoint
admitt ance becomes very small (the impedance becomes very large, like we expect
for a parallel LCR circuit). The second resonance occurs near 4.85 Mhz and behaves
like a series resonance, i.e. where the admitt ance is a maximum and the coupled
resonat or looks like a series LCR circuit.
Class- E Tesla coil notes, Bill Slade 6
We can simulate this behaviour using the circuit model in Fig. 5.
Assembling the circuit equations in the frequency domain:

V
i
0

=
[
R
s
+ j oL
1
j ok
.
L
1
L
2
j ok
.
L
1
L
2
j oL
2
+1/ j oC
]
I
1
I
2

,
Class- E Tesla coil notes, Bill Slade 7
Figure 4: The primary feedpoint admittance of a lossless TC resonator. (The primary
is in series with a 50 ohm resistor.)
Figure 5: Circuit model of the coupled resonator. If Rs=50, L1=10uH, L2=196.8uH
and C=5.805p. Coupling coefficient k = 0.24.
where the current s I are the loop current s on both sides of the transfor mer.
To find the admitt ance seen by the voltage source, solve for I
1
:
I
1
=V
i
j oL
2
+1/ j oC
( R
s
+ j oL
1
)( j oL
2
+1/ j oC)+o
2
k
2
L
1
L
2
This can be modified slightly for more attractive present ation as well as solving for
the admittance:
Y
i
=
1o
2
L
2
C
( R
s
+ j oL
1
)(1o
2
L
2
C)+ j k
2
o
3
L
1
L
2
C
The plot of the admittance Y
i
versus frequency for this circuit model is seen in
Figure 6. Note from the formula that the parallel resonance occurs when
o=
1
.
L
2
C
,
i.e., the admitt ance vanishes (input impedance tends to infinity).
The rolloff above resonance is a bit sharper for the circuit model than for the NEC
model, because we are assumi ng in the circuit model a perfect LC circuit. The NEC
model contains a small resistance to account for slight radiation effects. However,
this model will provide a good starting point for circuit simulations of the Class- E
Class- E Tesla coil notes, Bill Slade 8
Figure 6: Plot of admittance seen by the voltage
source in the circuit model of Fig. 5.
amplifier based Tesla coil.
An import ant part of the modeling is to estimate the loading provided by the arc.
For the purpose of developing a matching network between the amplifier and the
coil resonat or, I assume a resonat or Q factor between 10 and 20. This is very
difficult to measure in practice, because the coil must be operating under high
power conditions. Furthermore, the characteristics of the arc depend on power
delivered to the coil and are also, by nature, time varying as a result of air
movement and plasma instabilities. An in- depth discussion of discharge properties
is beyond the scope of this paper, but is an active area of research.
2.2 Class E Amplifier and Matching
In this section, we touch on some of the important aspects of class- E switching
amplifier design. Starting from a simplified version of the topology found in [3], we
construct the basic output matching/ filter network (Figure 7).
Starting from the left of Figure 7, DC power is supplied to the circuit by the supply
VDD. The inductor RFC most have a sufficiently high value to block the RF from
going back into the power supply as well as to look like a current source at RF to
the switching/ filter circuit. If the inductive reactance is several hundred ohms at
the working frequency, this is sufficient. (At 4.5 MHz, 17 25uH should be
enough.) Do not make this inductor to big, otherwise it could resonate (with
possibly disastrous consequences). Also, if you wish to audio modulate the supply
(to make a "singing Tesla coil"), you do not want the audio rolloff to be to noticeable
in the treble range.
The switch shown usually takes the form of a power MOSFET or IGBT. In the
megahert z range, MOSFETs work well. (I use a 2SK2698. IRFP460 may be used, but it
has a higher gate capacitance and is therefor more difficult to drive.) The switch is
made to open and close only when the voltage across the switch is close to zero.
This greatly reduces the power dissipat ed in the transist or during on- off switching
transient s (when the transistor is in its linear region, i.e. looks like a resistor). This
means that the timing of the on and off switching must be carefully controlled.
This is accomplished through the careful design of the RLC circuit to the right of
Class- E Tesla coil notes, Bill Slade 9
Figure 7: Topology of the class- E switching amplifier.
the switch.
Using the rule of thumb provided on the Class- E forum [4], we design Ls to have a
reactance of about X
L2
=3* 0.56 * VDD/IDD
max
for operating into a load Rload 50
ohms. (For a more systematic set of design rules, see [5].) From there we will use
SPICE simulations to optimise its value. The values of Cs and Cp should be chosen
to resonate (including the transist or drain capacitance) with the coil L2 near the
operating frequency. Given our choice of inductor, we will have created a low Q
resonant circuit (assuming a 50 ohm load resistance). The value for Cp will
ultimately have to be tweaked, since real transist or drain capacitances will vary
slightly. Generally, smaller values of Cp will mean higher instantaneous drain
voltages. Care should be taken to ensure that the transist or maximum tolerable
drain voltage is not exceeded. Use slightly larger values than those indicated by
simulation and work downwards in capacitance until desired performance is
obtained. Ct is a shunt load tuning capacitor. An air- variable capacitor is ideal for
this service (30- 800pF). This is used to achieve a good match and to tune for class-
E operation for load variations (this will be import ant for good Tesla coil operation).
In order to ensure that we have found some good starting values for the matching
network, a time- domain SPICE simulation is carried out on the following netlist:
VIN 100 0 DC 115.0
LDD 100 1 250u IC=0
VGG 201 0 SIN(0.0 15.0 4.69meg 0 0)
RGG 201 200 4.7
XQ1 1 200 0 STW14NM50
RDUM 1 0 100000
CDD 1 0 270p
LS 1 2 2.5u
CP 3 0 720p
RLOAD 3 0 50
.OPTIONS NOPAGE RELTOL=1.0E-8
.END
Notice that we have replaced the idealised switch with a model for the 2SK2698
MOSFET whose gate is driven by a time- domain sinusoi dal source.
Using these values, we perform a simulation that yields reasonable Class- E drain
voltage waveform seen in Figure 8.
Class- E Tesla coil notes, Bill Slade 10
Notice the phase lag of the load voltage with respect to the drain voltage as well as
the slight distortion of the output voltage waveform on the load. Since we are
developing this circuit for a Tesla coil (instead of a radio transmit ter), we do not
worry so much about this distortion. A radio transmi t t er would need additional
filtering to ensure low harmonic output.
Now that we have an idea of what the amplifier looks like, let us replace the 50 ohm
load with the circuit model of the Tesla coil resonat or in Figure 9.
Table 1 gives the values of the component s that yield good simulation results.
Component Value Notes
VDD 100V DC power supply
RFC 50uH RF choke
SW Use 2SK2698 switched w/12V sinusoi d
Cp 270pF This is addition to the drain capacitance
of the 2SK2698 (about 600pF)
Cs 2700pF
Ls 2.1uH
Ct 270pF This will depend heavily on TC loading
Lp 1uH primary winding
Lr 17.68uH secondary
Class- E Tesla coil notes, Bill Slade 11
Figure 8: SPICE Simulated waveforms for the simple class- E output
stage shown in Figure 7. The switch is replaced with a model of the
2SK2698 MOSFET.
Component Value Notes
K 0.3 coupling coefficient
Cr 67.87p
Rr 10000 ohm for setting unloaded Q (here about 20)
Table 1: Matching circuit component values.
Note that the coupling coefficient is somewhat different than that predicted by the
resonat or modeling. This is because the perfor mance of the coil depends strongly
on the loading from the arc (the loaded resonat or Q). The load that appears at the
feedpoint depends on a combination of the Q and the coupling. These are basically
determi ned using a decidedly unscientific trial - and- error process. We can be
satisfied that the coupling coefficient is within 20% of that predicted by the
resonat or modeling.
The last row in the table is the equivalent resistance of the secondary. We have set
it such that the resonat or Q is about 20 (simulating the effect of the arc loading).
Note that this a much oversimplified model of the Tesla coil resonat or (for example,
the actual voltage magnification is not modeled, nor does this represent a good
model of the arc discharge). It will suffice, however, to put some starting values on
the matching circuit component s.
A Spice simulation yields the results in Figure 10.
Class- E Tesla coil notes, Bill Slade 12
Figure 9: Circuit model of matching network for
class- E Tesla coil.
The simulation results show well timed drain switching transitions. The switch
opens and closes when the voltage is close to zero, which is the condition for class-
E operation. We also see that the Tesla coil primary voltage and current is rich in
harmonics. This is not a problem, because we want to make sparks, not a radio
transmi t t er. This is why the entire coil should be well shielded in an RF tight
enclosure (Faraday cage).
In practical Tesla coil service, it is difficult to maintain good class- E operation, but
by careful tuning, efficient (although not perfect) switching behaviour can be
attained. Figure 11 shows a typically attainable power amplifier drain waveform.
Class- E Tesla coil notes, Bill Slade 13
Figure 10 : Time domain waveforms for Tesla coil driven near
Class- E operation.
The waveform has the tendency to change as the Tesla coil discharge power varies
or the primary/ secondary windings heat up and expand, slightly changing the
coupling. The parallel variable capacitor can be used to compensat e for these
changes. Of course this is a manual adjust ment that is somewhat difficult to
automat e. Some improvement to primary/ secondary design to reduce thermal
expansion would undoubt edly help.
2.3 The PLL and oscillator chain
Since we use a phase locked loop to auto- tune the Tesla coil, it is worth reviewing
some basic theory behind the PLL [6]. Most basic frequency multiplying (integer - N)
PLLs have a block diagram that looks somet hi ng like Figure 12.
A reference signal is applied to the input to the phase comparat or. If you were
making a frequency synt hesi zer, this might be a signal from a highly stable crystal
Class- E Tesla coil notes, Bill Slade 14
Figure 12: Generic phase- locked loop.
Figure 11: Scope shot of power MOSFET drain
waveform during operation of the Tesla coil.
oscillator. In our case, it will be a signal proportional to the voltage at the top of the
Tesla coil resonator. The phase comparat or in our circuit is essentially a balanced
mixer like those found in most radio circuits. The reference signal is "mixed" with
the frequency divided signal from the voltage controlled oscillator producing both
low and high frequency component s. Only the low frequency component s pass
through the low- pass filter. These low frequency component s steer the voltage
controlled oscillator such that the frequency divided VCO output and the reference
signal are always exactly 90 degrees out of phase, simultaneously keeping the VCO
frequency exactly N times the reference frequency.
If the loop is close to the locked state, we can perfor m a linear analysis of the phase
behavior. First, let us list the pertinent variables in Table 2.
Variable Label Notes
Reference phase
ref
Phase detector output voltage V

Phase detector gain K

units of volts/ r adi an

Low pass filter transfer function H(s)
VCO input voltage V
tune
VCO tuning gain K
VCO
units of Hz/volt
Divider ratio N
Divider phase
N
Table 2: Variables associated with linear PLL analysis.
We can treat the system in Figure 11 as a linear feedback system with the VCO
tuning voltage as the output and the reference phase as the input. Remembering
that the phase comparat or (mixer) gives us the difference between the reference
phase and the divider phase. Hence,
V

=K

(
ref

N
)
.
The tuning voltage (in the frequency domain) of the VCO is then
V
tune
=H( s) K

(
ref

N
)
The tuning voltage, in reality, does not change the phase of the VCO, but its
frequency. In terms of phase, this means
d
VCO
dt
=K
VCO
V
tune
.
In the frequency domain, the VCO phase can be written as
Class- E Tesla coil notes, Bill Slade 15

vco
=
K
VCO
V
tune
s
,
where we substit ute s for d/dt.
Remembering that the divider also "divides" the VCO phase (an exercise to the
reader: convince yourself of this), we can close the loop and get
V
tune
=H( s) K

ref

K
VCO
V
tune
/ N
s
)
.
After some rearrangement, we can put the VCO tuning voltage in terms of the
reference phase:
V
tune

ref
=
s H(s) K

s+
K
phi
K
VCO
N
H( s)
.
Putting this in terms of reference frequency (by setting
o
ref
=s
ref
) yields the
classic PLL closed- loop transfer function
Y (s)=
o
VCO
No
ref
=
(H( s)
s+(H( s)
,
where
(=
K
VCO
K

N
.
The variable is usually set by the PLL chip and VCO (although we may be able to
change the divide ratio).
The key to designing the PLL lies in finding a good filter transfer function H(s) that
yields the tracking speed we need while simultaneously remaining stable. This can
be done by ensuring that the poles of the transfer function all lie well on the left -
hand- side of the complex plane. Alternatively, at the point where the magnitude of
the transfer function lies on the edge of the unit disk in the s- plane, there should
be a good phase margin away from 180 degrees (the condition for oscillation
instability).
2.3.1 A design exampl e
Let us start with a simple example: a loop low pass filter that is just a simple RC
circuit where
H(s)=
1
1+st
and is the time constant of the RC circuit. The transfer function can now be
written as
Class- E Tesla coil notes, Bill Slade 16
Y (s)=
(/(1+st)
s+(/(1+st)
.
This can be rearranged into
Y (s)=
(/ t
s
2
+s/ t+(/t
.
we see we have created a second- order PLL using a first - order RC low pass filter.
The poles of Y(s) lie at
s=
1
2t
( 1!
.
14(t)
.
If (t>1/ 4 , then the system is said to be underdamped. If there is a sudden
change in reference frequency, the VCO output frequency will exhibit damped
oscillatory behaviour. According to the linear theory, these oscillations will damp
out over time. Keep in mind, however, that this linear model is an approximation of
a nonlinear system. If the oscillations are large, this model breaks down, because it
cannot account for the nonlinear instability that can occur if the frequency
excursions are too large. For this reason, if the linear theory predicts highly
underdamped solutions, expect instability to appear.
If (t1/ 4 , then the PLL is overdamped. Here stability is not generally a
problem. However, slow locking and poor tracking can be problems of the loop is
overly damped.
The ideal situation is when (t=1/ 4 . This is the critically damped situation,
which exhibits the fastest locking and tracking times for a given loop bandwidt h.
This allows us to produce the following design rule for the second order PLL:
K
VCO
K

N
=
1
4RC
.
2.3.2 A "real" PLL design exampl e
Let us consider a somewhat different filter topology. By adding a second resistor
and capacitor as in Figure 13, we can achieve more control and better stability over
the frequency response of the loop (than with the simple filter in the preceding
section). This is the famous "lead- lag" filter often used in PLLs.
Class- E Tesla coil notes, Bill Slade 17
The new filter transfer function is
H(s)=
1+st
2
s
2
t
1
t
2
+st
3
+1
,
where
t
1
=R
1
C
1
, t
2
=R
2
C
2
and
t
3
=R
1
(C
1
+C
2
)+R
2
C
2
.
This is a bit of a mess to
insert into the PLL transfer function, so let us present a practical example. For the
NE564 PLL used in the Tesla coil, we shall use the parameters in Table 3 (optimised
by trial - and- error substit ution using readily available capacitor and resistor values
into the transfer function until we get a curve that gives good, not excessively
peaked response). It is also import ant to keep the rolloff well above the audio
range if we want to use drain modulation for creating good quality audio from the
arc. This is because as the modulat or changes the arc power, the PLL needs to
track the shift in resonant frequency of the Tesla coil. This improves the linearity
of the audio response. Note also that
R
1
=1.3K
is fixed internally by the NE564
chip.
Filter element Value
R
1
1.3K
C
1
4.7nF
R
2
100
C
2
47nF
K
VCO
1.26x10
8
rad/ s / V
K

0.477 V/rad
N 4
Table 3: Filter component values and PLL parameters.
Class- E Tesla coil notes, Bill Slade 18
Figure 13: 3rd order filter used in the Tesla coil.
Figure 14 is the closed- loop response of our PLL. It exhibits - 3dB rolloff around
300kHz, which is more than suitable to allow the PLL to track audio variations in
the coil loading while still attenuati ng the VCO signal well in the PLL loop.
Figure 15 shows the PLL filter response by itself). Here we see the effect of the two
filter poles (that lie near 4400Hz and 790kHz)and a zero at 34kHz.
The stability of the PLL can be measured by the amount of phase margin there is in
the denominat or of the PLL transfer function. Generally speaking, we encount er
instability if the denomi nat or approaches zero, viz.
(H(s)
s
-1 .
We can plot the left - hand- side of this expression versus frequency and look where
the magnit ude approaches unity (0 dB). The correspondi ng distance between the
0dB point on the phase plot and 180 degrees gives the phase margin (in Figure
Class- E Tesla coil notes, Bill Slade 19
Figure 14: Closed loop response curves for 3rd
order PLL.
Figure 15: Loop filter transfer function.
16). It should generally be more than 45 for good perfor mance.
Figure 16 shows that we have nearly 60 phase margin (seen at f 700kHz, where
the red loop gain curve crosses the 0dB grid), so the PLL should remain stable.
2.4 Notes on implementation and circuit diagrams
2.4.1 Quadrature generation
The PLL oscillator generates a signal around 22.5MHz. By using two D flip- flops in
a circular shift register configuration, we can divide the frequency by four and have
4.5 MHz signals available at 0, 90, 180 and 270 degrees. The circuit is in Figure
17.
Class- E Tesla coil notes, Bill Slade 20
Figure 16: Plot for computing phase margin.
The 74F74 TTL flip- flop is used, but any chip capable of working above 25MHz
should be fine.
2.4.2 The RF generator and Tesla coil apparatus
Figure 18 shows the full schematic of the Tesla coil system (without modulator or
power supply).
Class- E Tesla coil notes, Bill Slade 21
Figure 17: Quadrature generator/ f requency
divider using two D flip- flops.
Class- E Tesla coil notes, Bill Slade 22
Figure 18: Schematic: PLL tuned class- E Tesla coil.
Number Part number Description Supplier
1 NE564 PLL/VCO syst em Digikey
1 74F74 Fast TTL D flip- flop Digikey
1 IXDD414 MOSFET Gate Driver Digikey
1 2SK2698 15A/ 600V N- Ch power MOSFET Digikey
1 7805 Voltage regulat or Digikey
1 7812 Voltage regulat or Digikey
2 330R Resistor 1/ 4W 1206 chip Digikey
2 1K0 Resistor 1/ 4W 1206 chip Digikey
2 100R Resistor 1/ 4W 1206 chip Digikey
1 150R Resistor 1/ 4W 1206 chip Digikey
1 1K0 pot variable resist or, 1/ 4 W Digikey
1 1.0R Resistor, 2W, axial Digikey
1 0.47uF Capacitor, poly, 400V Digikey
2 100pF Capacitor, ceramic NPO, 603 chip Digikey
1 100pF Capacitor, silver - mica, 500V Digikey
2 4.7nF Capacitor, poly., 100V Digikey
2 47nF Capacitor, poly., 100V Digikey
2 100nF Capacitor, poly., 100V Digikey
3 4.7uF Capacitor, tant., 16V Digikey
2 470nF Capacitor, poly., 100V Digikey
2 10pF Capacitor, ceramic, NPO,603 chip Digikey
1 2700pF Capacitor, silver - mica, 500V Digikey
1 70- 1000pF Capacitor, air- variable, 250V RF Parts
1 100uF Capacitor, electrolytic, 50V Digikey
1 1000uF Capacitor, electrolytic, 50V Digikey
2 Iron pwdr core Amidon mix 2 Reichelt Electronics
20m 1.5 mm Cu wire enameled wire for coils Reichelt Electronics
25m 1.5mm Cu wire Insulat ed wire for secondary Local hardware
45cm 9cm diam PVC pipe windi ng form Local hardware
1 Faraday cage See text
1 enclosure for PCB Local supplier
4 BNC connect or s For enclosure and Faraday cage Local supplier
assrt' d hardware Local hardware
1 PCB Local supplier
1 Heat sink Digikey
Table 4: Bill of Materials, PLL tuned Tesla coil.
2.5
Class- E Tesla coil notes, Bill Slade 23
3. The modulator
Figure 19 shows the schematic of the audio modulator.
Class- E Tesla coil notes, Bill Slade 24
Figure 19: The audio modulator schematic.
Number Part number Description Supplier
1 TL494 PWM/SPMS controller Digikey
2 TC4422 Power MOSFET gate driver Digikey
2 IRFP460 Power MOSFETs Digikey
1 7812 12V/ 1A Voltage regulator Digikey
2 1N4148 Silicon general purpose diode Digikey
2 360V MOV 5A/ 360V MOV for clamping drain Digikey
4 HFA15PB60 600V/ 15A ultra- fast diodes Digikey
4 Ferrite cores See schematic & text Digikey
3 10K Resistor, 1/4W, 1206 chip Digikey
2 330R Resistor, 1/4W, 1206 chip Digikey
2 2.0R Resistor, 1/4W, 1206 chip Digikey
1 1K pot Potentiomet er, 1/4W Digikey
1 470pF Capacitor, ceramic, NPO, 603 chip Digikey
2 10uF Capacitor, elect., 50V Digikey
1 0.47uF Capacitor, poly, 50V Digikey
1 4.7uF Capacitor, tant., 16V Digikey
1 470uF Capacitor, elect., 50V Digikey
1 0.22uF Capacitor, poly, 630V local supplier
1 1.0uF Capacitor, poly, 630V local supplier
1 PCB FR- 4, double sided local supplier
1.0mm enameled wire Reichelt
Asst' d. hardware local supplier
Table 5: Bill of materials, modulator.
The modulat or operates at a clock frequency of about 200kHz. This helps to keep
the transfor mer small and the sound quality good. The transfor mer is made of four
ferrite ring cores stacked end- to- end to improve the power handling (we need to
control up to 200- 300 watts), so a conservative approach to sizing the transfor mer
core is good. Seventeen turns of 1mm enameled wire are tightly wound as a
secondary on the four cores. Cover the cores with a layer of PVC electricians' tape
first, to prevent scoring the enamel on the wire (and possible short circuits). A
layer of electrical tape is also put on top of the secondary before winding a bifilar
centre- tapped primary (each primary winding has 17 turns). See Figure 20 for the
finished transfor mer. When connecting the primary to the MOSFET drains, be sure
the transfor mer senses are correct, or you will see fire and smoke on power - up!!
Design your circuit board to be double sided, with one side as a ground plane to
enhance perfor mance and to avoid RFI problems.
Class- E Tesla coil notes, Bill Slade 25
It is important that the MOSFETS are mount ed on a suitable heatsink. Also, the fast
rectifier diodes will need heatsinking for sustained high power operation. However,
this modulat or is highly efficient (over 95% at 250W output power), so large
heatsinks are not necessary. Mounting the modulator PCB (and hence, heatsinking
the MOSFETs and ultra- fast rectifiers to the box wall) in a die cast aluminium box
(also providing good RFI shielding) may be sufficient.
This modulat or gives reasonable audio performance in an efficient manner.
However, the use of a dedicated filter is recommended to between the modulat or
and the RF amplifier drain input. Two things are worth noting about the existing
circuit in Figure 19:
The capacitor that follows the bridge rectifier will cause high current peaks
through the diodes in the bridge, particularly when pulse duty cycle is less
than 50%. This reduces efficiency and can stress the diodes. A series
inductor here would reduce stress on the diode bridge.
The simple capacitor / i nduct or L- network may not provide enough RF
decoupling to keep conduct ed RF into the power supply as small as possible.
Figure 21 shows how the PA stage is connected to the modulat or via a L- C- L T-
network. Figure 22 shows the response of this filter. It is slightly peaked and has a
cutoff frequency of about 40kHz. At 4.5MHz, this filter should provide around
100dB of attenuation. Conducted RF should be on the order of millivolts on the DC
supply side, if good layout and enclosures are used. For the 25uH inductor, use RF
grade powdered iron cores. Low- loss, high permeability ferrite should be used for
the 150uH inductor.
Class- E Tesla coil notes, Bill Slade 26
Figure 20 : Modulator prototype board being tested.
Finished transformer seen at bottom.
Class- E Tesla coil notes, Bill Slade 27
Figure 21 : Recommended implement ation of the RF blocking filter
between RF power amplifier and audio modulator.
4. The DC power suppl y
The power supply is relatively straightforwar d. Given the voltages and current s
involved, make sure that all wiring is suited for the current. (I used 1.5mm copper
wire for all power connections in this circuit.) Fuses or circuit breakers are
absolutely necessary. If a power MOSFET fails and suffers a short circuit, there
must be a fuse or circuit breaker present to prevent a fire! Also, since mains
voltages are present on the transfor mer primary and high secondary voltages are
present in the circuit, all connections must be insulated well and inaccessible to
curious fingers or inadvertent bodily contact.
Class- E Tesla coil notes, Bill Slade 28
Figure 23 : Schematic of power supply.
Figure 22: Frequency response of RF- blocking low- pass filter.
5. The Faraday cage
A very important part of this experiment was the reduction of injury risks and
harmful interference. For this reason a wire- mesh enclosure like that shown in
Figure 24 was constructed.
The purpose of the Faraday cage is twofold. It helps prevent accident al contact with
the energised coil by presenting a physical barrier to those observing the
experiment. Additionally, it greatly attenuat es the electromagnetic fields present in
the vicinity of the coil, thereby reducing personal exposure to strong fields as well
as reducing coupling into nearby metal objects that may act as inadvertent
antennas.
Some care must be taken in the const ruction of the Faraday cage. Most import ant
is the electrical integrity of all joints in the wire mesh. This means all joints should
be tightly clamped or soldered, as seen in Figure 25.
Where cables enter the cage, the ground must be well established near the entry
Class- E Tesla coil notes, Bill Slade 29
Figure 24: Coil inside of shielding
cage.
Figure 25 : Illustration of the solder joints needed for the
Faraday cage.
point by using proper connectors soldered or clamped to the mesh (Figure 26).
Otherwise, radiation from ground loops could present problems.
Coaxial cables are strongly recommended for RF power applications, although
closely twisted pairs will function reasonably well, particularly in balanced
(differential) transmi ssion lines.
Furthermore, be sure to mount the Tesla
coil driving circuit in an RF- tight box
(like the die cast box in Figure 27).
Bypass all DC and low frequency (audio)
input s so RF coupling into the power
supply is minimised. Keep all leads as
short as possible and read up on
electromagnetic compatibility. Then you
can apply the proper precautions for
preventing harmful interference. Use a
field strengt h meter (like that seen in
Figure 28) to check for possible
radiation with all shielding in place.
Take readings along power cables to see
if parasitic coupling is a problem.
Readings should be near zero more than
a meter or two from the Faraday cage. If
Class- E Tesla coil notes, Bill Slade 30
Figure 26: Coaxial cable entry points
through the mesh using BNC connectors.
Figure 27: PLL Tesla circuit seen mounted
in RF- tight box (with lid removed for
testing).
there are significant readings near the power cord where it plugs into the wall,
check your RF decoupling. A suitable radio receiver with an RSSI meter can also be
used for this measurement. It will be far more sensitive than a simple field-
strengt h meter and will give a good indication of any harmful radiation at large
distances (10s to 100s of meters) from the Tesla coil.
Remember that safety is your utmost responsi bility . Make sure your cables,
interconnect s, primary and secondary windings can handle the power and never
allow anyone to come in contact the plasma or any energised circuit. Use
appropriate fuses or circuit breakers.
Class- E Tesla coil notes, Bill Slade 31
Figure 28: Using a field strength meter to
check shielding effectiveness.
6. Review of specifications
In this section, some of the measured performance parameters are compared with
the initial "wish- list" specifications posed in the Introduction.
Tesla coil and RF stages are:
1. Power amplifier (PA) output: 200- 250 Watt: measured at 250W w/VDD=115V
2. PA supply: 100- 120VDC: Runs well at 115VDC
3. PA efficiency: > 90%: Achieved when well tuned
4. Operating frequency: 4.5 MHz: Without arc, resonant frequency is 4.53MHz.
With full power arc, drops to somewhere around 4.4 MHz.
5. PA input signal level: 5V (TTL- level): Input to IXDD414.
6. VCO freq range: 4.0- 5.0MHz: Satisfied.
7. PLL loop bandwidt h: >50kHz: PLL bandwidt h calculated to be around
300kHz.
8. BW of drain low- pass network: >15kHz: This has not been measured yet.
Filter needs to be implement ed.
9. Drain LP network attenuation at 4.5MHz: > 100dB: To be tested.
10. Measured RF at 300m: < 15uV/ m: Do not have instrument ati on to measure
this, but field strengt h meter shows no deviation on its most sensitive setting
when more than 2m from the Faraday cage.
Preliminary specifications for the modulator are:
1. Drain supply voltage: 100- 120V: Satisfied.
2. Output PWM duty cycle: 0 < d < 90%: Satisfied.
3. Clock frequency: 200kHz: Satisfied.
4. Output voltage: 100V: Output voltage to 108V using 115V power supply.
5. Clock ripple on power supply: < 0.5V: Satisfied.
6. Effective audio band: 20Hz 15kHz: Satisfied.
Be sure to follow all the Tesla coil discussions on htt p: / / 4hv. org/ !
Class- E Tesla coil notes, Bill Slade 32
6. Appendi x A: Notes on the NEC solver
The Numerical Electromagnetics Code (NEC) is a moment method solver for wire
antennas. The idea behind the model is fairly straightforwar d. A curved wire (see
Figure 27) is assumed to have a current flowing on it as a result of an incident
electric field or a voltage/ cur rent source connected to the wire. A scattered
electromagnetic field results from the current s on the wire.
Basically, NEC solves a form of the following integral equation along the surface of
the wire (whose geometry is modelled by lots of small straight line segment s) for
the current s I(l) along the wire given an incident electric field (from a voltage
source, in our case) E
i
.
E
i
(l)=
j j
4nk
0
(
k
0
2
+

2
l
2
)

C
I (l ') dl '
rr '
e
jk
0
(rr ')
.
While there is a lot of complicated detail in the solution of this equation, we are
interest ed in knowing the current that flows through the voltage source so we can
use Ohm' s law to compute the feedpoint impedance. NEC can do this
automatically.
Those readers interest ed in the theory and practice of electromagnetic modeling of
antennas and open wire struct ures are referred to the online literat ure [2], which
consists of user manuals and theoretical exposition.
Class- E Tesla coil notes, Bill Slade 33
Figure 29: Current carrying wire is
broken up into short straight segments.
Electric and magnetic fields in the space
surrounding the wire can then be found.
7. References
[1] http: / / www.easter nvoltageresearch.com/ design_resource.ht m
[2] NEC, Numerical Electromagnetics Code, [online], htt p: / / www. nec2.org/
[3] J. F. Davis and D. B. Rutledge, " A low- cost class- E power amplifier with sine
wave drive," IEEE MTT- S Int. Microwave Symp. Dig., vol.2, pp. 1113- 1116,
June 1998.
[4] Class- E Forum, [online], http: / / cl asse. monkeypuppet.com/
[5] N. O. Sokal, "Class- E RF power amplifiers," QEX Mag., Jan. - Feb.
2001, pp. 9- 19.
[6] K Shu and E. Sanchez- Sinencio, CMOS PLL Synthesizers: Analysis and
Design, Springer, 2005.
8. Document History
1. First version v1.0, 17 Jan., 2007
2. Version 1.1, 8 Feb. 2007. Added Figure 21, 22 on RF- blocking filter / audi o
filter. Added supporti ng text. Made other small changes to wording
throughout the document.
3. Version 1.2, 5 Mar. 2007: Changed schematics slightly. Added reference [1],
[5].
Class- E Tesla coil notes, Bill Slade 34